U.S. patent application number 13/561724 was filed with the patent office on 2013-05-09 for magnetic connector apparatus and related systems and methods.
This patent application is currently assigned to SPARKLING SKY INTERNATIONAL LIMITED. The applicant listed for this patent is Larry Hunts. Invention is credited to Larry Hunts.
Application Number | 20130113584 13/561724 |
Document ID | / |
Family ID | 47115541 |
Filed Date | 2013-05-09 |
United States Patent
Application |
20130113584 |
Kind Code |
A1 |
Hunts; Larry |
May 9, 2013 |
Magnetic Connector Apparatus and Related Systems and Methods
Abstract
A magnetic connector apparatus may comprise one or more magnet
housings, each of which may comprise one or more magnets positioned
therein to rotate within the magnet housing(s). The apparatus may
be configured using one or more safety features in order to prevent
access and/or removal of the magnet(s). In some embodiments, the
apparatus may further comprise an inner retainer piece coupled with
the one or more magnet housings, a first outer housing piece
coupled with the inner retainer piece, and a second outer housing
piece coupled with the inner retainer piece. The first outer
housing piece may be positioned on an opposite side of the
connector apparatus from the second outer housing piece such that
the inner retainer piece is positioned in between the first outer
housing piece and the second outer housing piece. Novel methods for
manufacturing a magnetic connector apparatus are also
disclosed.
Inventors: |
Hunts; Larry; (Dongguan,
CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hunts; Larry |
Dongguan |
|
CN |
|
|
Assignee: |
SPARKLING SKY INTERNATIONAL
LIMITED
Wan Chai
HK
|
Family ID: |
47115541 |
Appl. No.: |
13/561724 |
Filed: |
July 30, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13297953 |
Nov 16, 2011 |
|
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13561724 |
|
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61555392 |
Nov 3, 2011 |
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Current U.S.
Class: |
335/285 |
Current CPC
Class: |
H01F 7/0252 20130101;
H01F 7/0242 20130101; Y10T 24/32 20150115 |
Class at
Publication: |
335/285 |
International
Class: |
H01F 7/02 20060101
H01F007/02 |
Claims
1. A magnetic connector apparatus, comprising: a magnet housing; a
magnet positioned within the magnet housing such that the magnet
can rotate within the magnet housing, wherein the magnet is
configured to be magnetically connected with a second magnet
positioned within a second magnet housing of second magnetic
connector apparatus without the magnet and the second magnet
directly contacting one another; an inner retainer piece coupled
with the magnet housing, wherein the inner retainer piece comprises
a magnet housing receiver configured to engage the magnet housing
to couple the magnet housing to the inner retainer piece; a first
outer housing piece coupled with the inner retainer piece; and a
second outer housing piece coupled with the inner retainer piece,
wherein the first outer housing piece is positioned on an opposite
side of the connector apparatus from the second outer housing piece
such that the inner retainer piece is positioned in between the
first outer housing piece and the second outer housing piece, and
wherein the magnet housing is positioned to extend along a
peripheral connection edge of the inner retainer piece, along a
peripheral connection edge of the first outer housing piece, and
along a peripheral connection edge of the second outer housing
piece such that the magnetic connector apparatus is configured to
be magnetically connected with the second magnetic connector
apparatus along a peripheral connection edge of the magnetic
connector apparatus defined at least in part by the inner retainer
piece, the first outer housing piece, and the second outer housing
piece.
2. (canceled)
3. The magnetic connector apparatus of claim 1, wherein the magnet
housing receiver comprises: a first magnet housing engaging member;
and a second magnet housing engaging member, wherein the first
magnet housing engaging member is configured to engage a first end
of the magnet housing, and wherein the second magnet housing
engaging member is configured to engage a second end of the magnet
housing opposite from the first end.
4. The magnetic connector apparatus of claim 3, wherein the first
magnet housing engaging member comprises a first magnet housing
plug configured to at least substantially seal an opening in the
magnet housing at the first end, and wherein the second magnet
housing engaging member comprises a second magnet housing plug
configured to at least substantially seal an opening in the magnet
housing at the second end.
5. The magnetic connector apparatus of claim 4, wherein both
openings in the magnet housing are formed with an at least
substantially circular radius, wherein the first magnet housing
plug and the second magnet housing plug both have a radius of
curvature that at least substantially matches the radii of
curvature of the openings in the magnet housing.
6. The magnetic connector apparatus of claim 1, wherein the magnet
housing comprises: a body member comprising a cylindrical cavity,
wherein the magnet is positioned within the cylindrical cavity; and
a first plate member extending from the body member and coupled to
a first surface of the inner retainer piece.
7. The magnetic connector apparatus of claim 6, further comprising
a fastener for coupling the first plate member to the inner
retainer piece, wherein the first plate member comprises a fastener
opening for receiving the fastener.
8. The magnetic connector apparatus of claim 7, wherein the
fastener comprises a rivet.
9. The magnetic connector apparatus of claim 6, wherein the magnet
housing further comprises a second plate member extending from the
body member and coupled to a second surface of the inner retainer
piece opposite from the first surface.
10. The magnetic connector apparatus of claim 9, wherein the inner
retainer piece comprises: a first recessed region on the first
surface for receiving the first plate member; and a second recessed
region on the second surface for receiving the second plate
member.
11. The magnetic connector apparatus of claim 1, further comprising
an enclosure encasing the magnet, wherein the enclosure is
positioned within the magnet housing, and wherein the apparatus is
configured such that the enclosure is rotatable with respect to the
magnet housing.
12. The magnetic connector apparatus of claim 1, further comprising
an enclosure encasing the magnet, wherein the enclosure is
positioned within the magnet housing, and wherein the apparatus is
configured such that the enclosure is fixed with respect to the
magnet housing and such that the magnet is rotatable with respect
to the enclosure.
13. The magnetic connector apparatus of claim 1, wherein the magnet
housing is positioned along a connection edge of the magnetic
connector apparatus, and wherein the connection edge is configured
to be magnetically connected with a connection edge of another
magnetic connector apparatus.
14. The magnetic connector apparatus of claim 1, wherein the magnet
housing comprises at least two redundant safety features for
preventing the magnet from being removed from the magnet
housing.
15. The magnetic connector apparatus of claim 14, wherein the at
least two redundant safety features comprise one or more of a
stainless steel material, a sonic weld, a magnet housing engaging
member configured to at least substantially plug one or more
openings in the magnet housing, a reinforced region wherein
material of the magnet housing is thicker, a rivet for coupling the
magnet housing to the inner retainer piece, and a recessed region
for receiving a portion of the magnet housing.
16. A magnetic connector apparatus, comprising: a first magnet
housing; a first magnet positioned within the first magnet housing
such that the first magnet can rotate within the first magnet
housing, wherein the first magnet comprises a multi-pole magnetic
assembly comprising a first half and a second half extending
substantially along a longitudinal axis of the multi-pole magnetic
assembly, the first half comprising at least two magnetic sections
of alternating polarity and the second half comprising a
corresponding number of magnetic sections, each magnetic section in
the second half having a polarity opposite that of an adjacent
magnetic section in the first half; an inner retainer piece coupled
with the first magnet housing such that the first magnet housing is
positioned along a first connection edge of the magnetic connector
apparatus; a second magnet housing, wherein the first and second
magnet housings comprise: a body member comprising a cylindrical
cavity, wherein a magnet is positioned within the cylindrical
cavity; a first plate member extending from the body member and
coupled to a first surface of the inner retainer piece; a second
plate member extending from the body member and coupled to a second
surface of the inner retainer piece opposite from the first
surface; and a fastener extending through an opening in at least
one of the first and second plate members and through an opening in
the inner retainer piece; a second magnet positioned within the
second magnet housing such that the second magnet can rotate with
the second magnet housing, wherein the second magnet housing is
coupled with the inner retainer piece such that the second magnet
housing is positioned along a second connection edge of the
magnetic connector apparatus, and wherein the second magnet
comprises a second multi-pole magnetic assembly comprising a first
half and a second half extending substantially along a longitudinal
axis of the second multi-pole magnetic assembly, the first half
comprising at least two magnetic sections of alternating polarity
and the second half comprising a corresponding number of magnetic
sections, each magnetic section in the second half having a
polarity opposite that of an adjacent magnetic section in the first
half; a first outer housing piece coupled with the inner retainer
piece; and a second outer housing piece coupled with the inner
retainer piece, wherein the first outer housing piece is positioned
on an opposite side of the connector apparatus from the second
outer housing piece such that the inner retainer piece is
positioned in between the first outer housing piece and the second
outer housing piece.
17. A method for manufacturing a magnetic connector apparatus, the
method comprising the steps of: providing a first outer housing
piece; providing a second outer housing piece; providing an inner
retainer piece, wherein at least one of the first outer housing
piece and the second outer housing piece comprises at least one
weld joint protrusion, and wherein a melt chamber is positioned
adjacent to the at least one weld joint protrusion; providing a
magnet housing; positioning a magnet within the magnet housing such
that the magnet is rotatable within the magnet housing; coupling
the magnet housing to at least one of the first outer housing
piece, the second outer housing piece, and the inner retainer
piece; and sonic welding the first outer housing piece to the
second outer housing piece with the inner retainer piece positioned
in between the first outer housing piece and the second outer
housing piece, wherein the weld joint protrusion is positioned and
configured such that material from the weld joint protrusion melts
into the melt chamber during the sonic welding process such that
melted material within the melt chamber bonds the first outer
housing piece and the second outer housing piece to the inner
retainer piece as the melted material solidifies.
18. The method of claim 17, wherein both the first outer housing
piece and the second outer housing piece comprise weld joint
protrusions.
19. The method of claim 18, wherein both the first outer housing
piece and the second outer housing piece comprise melt
chambers.
20. The method of claim 19, wherein the first outer housing piece
is welded to the second outer housing piece such that the first
outer housing piece melt chamber is at least substantially aligned
with the second outer housing piece melt chamber during the
welding.
21. The method of claim 17, wherein the weld joint protrusion
comprises a V-shaped ridge formed adjacent to at least a portion of
a perimeter of at least one of the first outer housing piece and
the second outer housing piece.
22. The method of claim 17, wherein the first outer housing piece
comprises a plastic material, wherein the second outer housing
piece comprises a plastic material, wherein the inner retainer
piece comprises a plastic material, and wherein the step of sonic
welding comprises sonic welding the inner retainer piece to both
the first outer housing piece and the second outer housing
piece.
23. The method of claim 22, wherein the step of sonic welding
comprises melting material from the first outer housing piece weld
joint protrusion and material from the second outer housing piece
weld joint protrusion into a joint melt chamber formed at least in
part by the first outer housing piece melt chamber and the second
outer housing piece melt chamber.
24. A magnetic connector apparatus, comprising: a magnet housing; a
magnet positioned within the magnet housing such that the magnet
can rotate within the magnet housing; an inner retainer piece
coupled with the magnet housing, wherein the inner retainer piece
comprises a magnet housing receiver configured to engage the magnet
housing to couple the magnet housing to the inner retainer piece; a
first outer housing piece coupled with the inner retainer piece;
and a second outer housing piece coupled with the inner retainer
piece, wherein the first outer housing piece is positioned on an
opposite side of the connector apparatus from the second outer
housing piece such that the inner retainer piece is positioned in
between the first outer housing piece and the second outer housing
piece, and wherein the magnet housing comprises: a body member
comprising a cylindrical cavity, wherein the magnet is positioned
within the cylindrical cavity; and a first plate member extending
from the body member and coupled to a first surface of the inner
retainer piece.
25. The magnetic connector apparatus of claim 24, wherein the
magnet housing receiver comprises: a first magnet housing engaging
member; and a second magnet housing member, wherein the first
magnet housing engaging member is configured to engage a first end
of the magnet housing, and wherein the second magnet housing
engaging member is configured to engage a second end of the magnet
housing opposite from the first end.
26. The magnetic connector apparatus of claim 25, wherein the first
magnet housing engaging member comprises a first magnet housing
plug configured to at least substantially seal an opening in the
magnet housing at the first end, and wherein the second magnet
housing engaging member comprises a second magnet housing plug
configured to at least substantially seal an opening in the magnet
housing at the second end.
27. The magnetic connector apparatus of claim 26, wherein both
openings in the magnet housing are formed with an at least
substantially circular radius, wherein the first magnet housing
plug and the second magnet housing plug both have a radius of
curvature that at least substantially matches the radii of
curvature of the openings in the magnet housing.
28. (canceled)
29. The magnetic connector apparatus of claim 24, wherein the
magnet housing comprises at least two redundant safety features for
preventing the magnet from being removed from the magnet
housing.
30. The magnetic connector apparatus of claim 29, wherein the at
least two redundant safety features comprise one or more of a
stainless steel material, a sonic weld, a magnet housing engaging
member configured to at least substantially plug one or more
openings in the magnet housing, a reinforced region wherein
material of the magnet housing is thicker, a rivet for coupling the
magnet housing to the inner retainer piece, and a recessed region
for receiving a portion of the magnet housing.
31. The magnetic connector apparatus of claim 24, wherein the
magnet housing further comprises a second plate member extending
from the body member and coupled to a second surface of the inner
retainer piece opposite from the first surface.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 13/297,953 titled "MULTI-POLE MAGNETIC
CONNECTOR APPARATUS" and filed on Nov. 16, 2011, which claims the
benefit under 35 U.S.C. .sctn.119(e) of U.S. Provisional Patent
Application No. 61/555,392 filed on Nov. 3, 2011 and is also titled
"MULTI-POLE MAGNETIC CONNECTOR APPARATUS." Both of the foregoing
applications are hereby incorporated by reference in their
entireties.
TECHNICAL FIELD
[0002] This disclosure relates to magnetic connectors. More
particularly, this disclosure relates to magnetic connectors
configured to rotate in order to magnetically link two objects, and
related systems and methods, including housings and magnetic
assemblies for such magnetic connectors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Non-limiting and non-exhaustive embodiments of the
disclosure are described, including various embodiments of the
disclosure with reference to the figures, in which:
[0004] FIG. 1A illustrates a multi-pole magnetic assembly
configured with four magnetic sections of alternating
polarities.
[0005] FIG. 1B illustrates a multi-pole magnetic assembly
configured with eight magnetic sections of alternating
polarities.
[0006] FIG. 1C illustrates a multi-pole magnetic assembly
configured with N magnetic sections of alternating polarities.
[0007] FIG. 2 illustrates a multi-pole magnetic assembly configured
with six magnetic sections of alternating polarities, including
relatively larger center sections.
[0008] FIG. 3A illustrates a multi-pole magnetic assembly
configured with eight magnetic sections of alternating polarities
in an oblong configuration.
[0009] FIG. 3B illustrates a multi-pole magnetic assembly
configured with six magnetic sections of alternating polarities in
a rectangular prism configuration.
[0010] FIG. 4 illustrates a cylindrical multi-pole magnetic
assembly encased within a cylindrical enclosure.
[0011] FIG. 5 illustrates a rectangular prismic multi-pole magnetic
assembly encased within a cylindrical enclosure.
[0012] FIG. 6 illustrates a cylindrical multi-pole magnetic
assembly encased within a triangular prismic enclosure.
[0013] FIG. 7A illustrates a connector apparatus including two
cylindrical multi-pole magnetic assemblies configured to rotatably
align polarities in order to magnetically link two sections of a
fabric.
[0014] FIG. 7B illustrates a connector apparatus including two
cylindrical multi-pole magnetic assemblies with aligned polarities
magnetically linking the two sections of fabric.
[0015] FIGS. 8A-8B illustrate a first multi-pole magnetic assembly
rotating about a longitudinal axis to align the polarities of its
magnetic sections with those of a second multi-pole magnetic
assembly.
[0016] FIGS. 8C-8D illustrate the first multi-pole magnetic
assembly rotating about its longitudinal axis in order to
magnetically link with the second multi-pole magnetic assembly
longitudinally askew along an outer perimeter.
[0017] FIGS. 9A-9G illustrate a first multi-pole magnetic assembly
and a second multi-pole magnetic assembly rotatably interacting and
maintaining a magnetic link while the second multi-pole magnetic
assembly is longitudinally translated along the outer perimeter of
the first multi-pole magnetic assembly.
[0018] FIG. 10A illustrates a connection member including three
connection edges forming a triangular framework, including a
multi-pole magnetic assembly adjacent each connection edge.
[0019] FIG. 10B illustrates a connection member including three
connection edges forming a triangular framework, including a
magnetic assembly and enclosure combination adjacent each
connection edge.
[0020] FIG. 10C illustrates a connection member including three
connection edges in a triangular configuration, including a
magnetic assembly and enclosure combination adjacent each
connection edge.
[0021] FIG. 10D illustrates a connection member including three
connection edges in a triangular framework, including a rotatable
multi-pole magnetic assembly adjacent each connection edge.
[0022] FIG. 11 illustrates a connection member including three
connection edges in a triangular configuration, each connection
edge including a cylindrical enclosure encasing a rectangular
prismic multi-pole magnetic assembly.
[0023] FIG. 12 illustrates a connection member including six
connection edges in a hexagonal configuration, including a magnetic
assembly and enclosure combination encased adjacent each connection
edge.
[0024] FIG. 13A illustrates a first connector apparatus including a
first connection member having four connection edges arranged in a
rectangular configuration, and a second connector apparatus having
four connection edges arranged in a rectangular configuration.
[0025] FIG. 13B illustrates the first and second connector
apparatus magnetically linked along aligned outer perimeters.
[0026] FIGS. 14A-14B illustrate a multi-pole magnetic assembly
adjacent a connection edge of a connection member rotating in order
to magnetically link with a second connector apparatus along askew
outer perimeters.
[0027] FIGS. 15A-15B illustrate first and second connector
apparatus magnetically linking along askew outer perimeters.
[0028] FIG. 16A illustrates a connector apparatus including a
rectangular connection member in the process of being magnetically
linked to four triangular connection members, including rotatable
magnetic assembly and enclosure combinations adjacent each
connection edge of each connection member.
[0029] FIG. 16B illustrates the connector apparatus including a
rectangular connection member magnetically linked to four
triangular connection members, the magnetic assembly and enclosure
combinations rotated such that opposite polarities are aligned.
[0030] FIG. 17 illustrates a connector apparatus comprising four
triangular connection members, including rotatably aligned magnetic
assembly and enclosure combinations magnetically linking each
connection edge of the four triangular connection members in order
to form a tetrahedron.
[0031] FIG. 18A illustrates a magnetizing apparatus configured with
a bottom plate and a hinged top plate configured to create a
multi-pole magnetic assembly.
[0032] FIG. 18B illustrates the magnetizing apparatus with two
magnetizable cylinders in place.
[0033] FIG. 18C illustrates a multi-pole magnetic assembly created
using the magnetizing apparatus.
[0034] FIG. 19 illustrates an exploded view of an embodiment of a
magnetic connector apparatus.
[0035] FIG. 20 illustrates a close-up view of a portion of an inner
retainer piece of the embodiment of FIG. 19.
[0036] FIG. 21 illustrates a close-up view of an embodiment of a
magnet housing of a magnetic connector apparatus.
[0037] FIG. 22 illustrates a perspective view of the magnetic
connector apparatus shown in FIG. 19.
[0038] FIG. 23A illustrates a cross-sectional view of various
components prior to undergoing a welding process in one
implementation of a method for manufacturing a magnetic connector
apparatus.
[0039] FIG. 23B illustrates a cross-sectional view of the
components shown in FIG. 23A after undergoing a welding
process.
[0040] FIG. 24A illustrates a cross-sectional view of various
components prior to undergoing a welding process in another
implementation of a method for manufacturing another embodiment of
a magnetic connector apparatus.
[0041] FIG. 24B illustrates a cross-sectional view of the
components shown in FIG. 24A after undergoing a welding
process.
[0042] In the following description, numerous specific details are
provided for a thorough understanding of the various embodiments
disclosed herein. The systems and methods disclosed herein can be
practiced without one or more of the specific details, or with
other methods, components, materials, etc. In addition, in some
cases, well-known structures, materials, or operations may not be
shown or described in detail in order to avoid obscuring aspects of
the disclosure. Furthermore, the described features, structures, or
characteristics may be combined in any suitable manner in one or
more alternative embodiments.
DETAILED DESCRIPTION
[0043] Described herein are embodiments of magnetic connector
apparatus that may comprise magnetic connectors configured to
rotate in order to magnetically link two objects. Such magnetic
connectors as described herein may comprise one or more magnet
housings. One or more magnets may be positioned within one or more
of the magnet housings such that the magnet(s) can rotate within
the magnet housing(s). In preferred embodiments, the magnet(s) may
comprise a neodymium magnet(s) or another high-strength/flux
magnet.
[0044] In some embodiments, the magnet housing(s) may be configured
to inhibit removal of the magnets for safety purposes. Because of
the high strength of neodymium magnets and other similar magnets,
it may be desirable to restrict access to such magnets to users of
a magnetic connector apparatus, particularly children. The dangers
associated with ingesting such magnets have been well documented.
Ingesting high-strength magnets can, in some cases, even lead to
death. It may therefore be desirable to construct the magnet
housing(s) in such a manner that access to the magnets contained
within such housings is restricted. This may be done in a variety
of ways, as described in greater detail.
[0045] For example, the material(s) used to form the magnet
housing(s) may be very rigid, durable, strong, and/or tough to
prevent a user (such as a child) from breaking the housing to allow
the magnet(s) contained therein to be removed or accessed. As
another example, sonic welding may be used such that various
components of the apparatus are sealed together in such a manner
that these components are difficult, if not impossible, to separate
by breaking the sonic weld. As still another example, one or more
components may be provided in order to at least substantially plug
one or more openings in the magnet housings to further restrict
access to the magnet within. As yet another example, part of the
magnetic connector apparatus may comprise one or more recessed
regions that may be configured to receive one or more portions of
the magnet housing to make it more difficult to remove the magnet
housing from the magnetic connector apparatus.
[0046] As still another example of a safety feature for restricting
access to the magnet(s), the magnetic connector apparatus may
include one or more fasteners for coupling the magnet housing to
another portion of the apparatus. In some preferred embodiments,
the fasteners may comprise rivets or other such fasteners that
cannot easily be removed by a user in order to further enhance the
safety features of the apparatus.
[0047] The magnet housing may also comprise one or more reinforced
regions wherein the material is thicker at locations that might
otherwise be vulnerable to wear, tampering, and the like.
Similarly, areas of the magnet housing adjacent to any opening for
receiving a fastener may be reinforced, appropriately bent, shaped,
or otherwise configured to further ensure that the magnet contained
therein cannot be removed and/or that the magnet housing cannot be
removed from the magnetic connector apparatus. In preferred
embodiments, multiple, redundant safety features/components are
incorporated into the apparatus to provide further protection
against unwanted access to the magnet(s). By providing redundant
safety features/components, such as a high-strength steel magnet
housing and sonic welding, the chances that a magnet may be removed
from the apparatus may be dramatically decreased, if not eliminated
altogether.
[0048] The magnet housing(s) may each be positioned along a
connection edge of the magnetic connector apparatus, such that the
connection edge is configured to be magnetically connected with a
connection edge of another magnetic connector apparatus. In this
manner, magnetic connector apparatus of various different shapes
and sizes may be coupled together to build larger structures, toys,
play games, etc.
[0049] As described in greater detail below, in some embodiments,
each magnet may comprise a multi-pole magnet assembly. Such an
assembly may comprise a first half and a second half extending
substantially along a longitudinal axis. The first half may
comprise at least two magnetic sections of alternating polarity and
the second half may comprise a corresponding number of magnetic
sections. Each magnetic section in the second half may have a
polarity opposite that of an adjacent magnetic section in the first
half such that the polarity of the magnet alternates along its
length. As described below, these assemblies may provide several
advantages that may be useful for certain implementations of the
inventions described herein.
[0050] However, various components and elements disclosed herein,
including but not limited to the magnet housing and, retainer
pieces, and housing pieces disclosed herein, may be used with other
types of magnets. For example, in some embodiments, the magnets
need not be configured such that they alternate in polarity along
their respective lengths. Instead, magnets with just two poles may
be used, such as those disclosed in U.S. Pat. No. 7,154,363 titled
"Magnetic Connector Apparatus," for example.
[0051] In some embodiments, the magnetic connector apparatus may
comprise a housing comprising an inner retainer piece coupled with
the magnet housing, a first outer housing piece coupled with the
inner retainer piece, and a second outer housing piece coupled with
the inner retainer piece. The first outer housing piece may be
positioned on an opposite side of the connector apparatus from the
second outer housing piece such that the inner retainer piece is
positioned in between the first outer housing piece and the second
outer housing piece.
[0052] In some embodiments, the magnetic connector apparatus may
further comprise a magnet housing receiver configured to engage the
magnet housing to couple the magnet housing to the inner retainer
piece. The magnet housing receiver may comprise one or more magnet
housing engaging members. In embodiments comprising two magnet
housing engaging members, a first magnet housing engaging member
may be configured to engage a first end of the magnet housing, and
a second magnet housing engaging member may be configured to engage
a second end of the magnet housing opposite from the first end.
[0053] In some embodiments, the first magnet housing engaging
member may comprise one or more magnet housing plugs. In
embodiments comprising two magnet housing plugs, a first magnet
housing plug may be configured to at least substantially seal an
opening in the magnet housing at the first end, and a second magnet
housing plug may be configured to at least substantially seal an
opening in the magnet housing at the second end.
[0054] The magnet housing may, in some embodiments, comprise a body
member comprising a cylindrical cavity. The magnet may be
positioned within the cylindrical cavity. The magnet may be
rotatable within the cavity or, alternatively, and as explained in
greater detail below, the magnet may be rotatable within another
enclosure positioned within the cavity. As still another
alternative, the magnet may be positioned within another enclosure
and the enclosure/magnet combination may be rotatable with respect
to the magnet housing.
[0055] One or more plate members may extend from the body member of
the magnet housing. The plate member(s) may be coupled to an outer
surface of the inner retainer piece. The magnetic connector
apparatus may further comprise one or more fasteners for coupling
the plate member(s) to the inner retainer piece. The fastener(s)
may be positioned through fastener openings within the plate
member(s) and/or inner retainer piece. The fastener(s) may comprise
a rivet, screw, bolt, pin, or the like.
[0056] In embodiments comprising magnet housings having two plate
members, a first plate member may extend from the body member and
be coupled to a first surface of the inner retainer piece. A second
plate member may extend from the body member and be coupled to a
second surface of the inner retainer piece opposite from the first
surface.
[0057] The inner retainer piece may comprise one or more recessed
regions on the inner retainer piece for seating/receiving the one
or more plate members. For example, a first recessed region may be
formed within or otherwise positioned on the first surface for
receiving the first plate member, and a second recessed region may
be formed within or otherwise positioned on the second surface for
receiving the second plate member.
[0058] The magnetic connector may further comprise an enclosure to
encase the magnet. The enclosure may be positioned within the
magnet housing. The enclosure may be configured such that it is
rotatable with respect to the magnet housing. Alternatively, the
enclosure may be fixed with respect to the magnet housing such that
the magnet is rotatable with respect to the enclosure (and the
housing).
[0059] The magnetic connector apparatus may comprise a plurality of
magnets/magnet housings, each of which may be positioned along a
connection edge of the apparatus such that multiple edges of the
apparatus may be used to magnetically couple the apparatus with
another magnetic connector apparatus. Each magnet positioned within
each of the magnet housings may be configured such that the magnet
can rotate within its respective magnet housing such that opposing
polarities of the magnets can be aligned and lock two or more
magnet connector apparatus together.
[0060] In some embodiments, two or more multi-pole magnetic
assemblies may be configured to rotate with respect to one another
in order to align opposite polarities and magnetically link two or
more components. According to various embodiments, a multi-pole
magnetic assembly may be cylindrical, rectangular, prismic, and/or
oblong. Alternative shapes are contemplated as well. A multi-pole
magnetic assembly may include any number of magnetic sections, each
adjacent magnetic section having an alternating polarity. Magnetic
assemblies may be encased within an enclosure, such as a
cylindrical or triangular prismic enclosure. Alternatively,
magnetic assemblies may be otherwise affixed to a connection member
or another component of the connector apparatus. For example, a rod
may be positioned to extend through a central axis of one or more
magnetic assemblies to facilitate the rotation.
[0061] In some embodiments, the multi-pole magnetic assembly may be
configured to rotate within and with respect to the enclosure. In
alternative embodiments, the enclosure encasing the multi-pole
magnetic assembly is configured to rotate. Enclosures and/or
magnetic assemblies forming part of a universal connector apparatus
may be configured to rotate with respect to one another in order to
align opposite polarities. In some embodiments, the magnetic
assemblies rotate with respect to the enclosures. In other
embodiments, the magnetic assemblies are fixed within their
respective enclosures and the enclosures rotate with respect to one
another in order to align the polarities of the encased magnetic
assemblies.
[0062] In some embodiments, connection members may be secured end
to end in order to form a triangle, square, rectangle, another
polygon, or another shape. Alternatively, connection members may be
joined together at the ends in order to form a polygonal framework
having any number of sides, or connection edges. A rotatable
multi-pole magnetic assembly may be positioned and rotatably
secured adjacent one or more edges of the polygon. For example, a
cylindrical magnet may be positioned adjacent each side of a
polygon. With regard to still other embodiments, solid objects,
such as triangles and squares, may include rotatable multi-pole
magnetic assemblies positioned adjacent one or more edges of the
polygonal solid object.
[0063] An enclosure may be fixedly secured adjacent one or more
side edges of a polygonal shape. Accordingly, in order to align
polarities, a magnetic assembly within each secured enclosure may
be configured to freely rotate in order to align polarities.
[0064] In other embodiments, two-dimensional objects, such as
squares, rectangles, and triangles, may be magnetically linked in
order to create three-dimensional objects, such as pyramids and
tetrahedrons.
[0065] In some embodiments of methods for forming the multi-pole
magnets, a magnetizing apparatus may be adapted to form a
multi-pole magnetic assembly, including multiple magnetic sections.
A bottom plate may be secured to a top press section via one or
more hinges. A cylindrical rod placed within the magnetizing
apparatus may then be used to create a multi-pole magnet.
[0066] Novel manufacturing methods and precursor components used in
such methods are also disclosed herein. In one example of such a
method for manufacturing a magnetic connector apparatus, an outer
housing piece may be provided that comprises one or more weld joint
protrusions.
[0067] In some embodiments, these weld joint protrusions may
comprise a V-shaped ridge formed adjacent to at least a portion of
a perimeter of the outer housing piece. Alternatively, the weld
joint protrusion may comprise another suitable shape, such as, for
example, a weld joint protrusion with a relatively flat top and/or
relatively parallel sides, rather than the relatively pointed tip
and slanted sides of a V-shaped ridge. A second outer housing piece
may also be provided. The second outer housing piece may also
comprise a weld joint protrusion.
[0068] One or both of the outer housing pieces may also be formed
with one or more melt chambers. The melt chamber(s) may be
positioned adjacent to the weld joint protrusion(s) such that
material from the weld joint protrusion(s) will melt into the melt
chamber(s) during a welding process, as described in greater detail
below. As described below, in preferred embodiments, the welding
process may comprise a sonic welding process.
[0069] In embodiments in which melt chambers are provided in both
of the outer housing pieces, the respective melt chambers may be
configured and positioned such that a the first outer housing piece
melt chamber is at least substantially aligned with a second outer
housing piece melt chamber during the welding process. In such
embodiments, material from the weld joint protrusion(s) may fill in
the partial melt chambers from both outer housing pieces (together
forming a joint melt chamber) such that, when the melted material
solidifies, it bonds to both of the outer housing pieces and, in
some implementations, an inner retainer piece as well. In some
embodiments, the joint melt chamber may be formed by a melt chamber
from an upper housing piece, a melt chamber from a lower housing
piece, and at least a portion of a surface of the inner retainer
piece. One or more of the outer housing pieces and/or inner
retainer piece may comprise a suitable material for sonic welding,
such as a thermoplastic material, a carbon fiber material, a
metallic material, or a composite material, for example.
[0070] As described elsewhere herein, one or more magnet housings
may also be provided, each of which may contain a magnet therein
such that the magnet is rotatable within the magnet housing. The
magnet housing(s) may be coupled to at least one of the first outer
housing piece, the second outer housing piece, and the inner
retainer piece. The first outer housing piece may then be sonically
welded to the second outer housing piece and/or the inner retainer
piece.
[0071] Reference throughout this specification to "one embodiment"
or "an embodiment" means that a particular feature, structure, or
characteristic described in connection with the embodiment is
included in at least one embodiment. Thus, the appearances of the
phrases "in one embodiment" or "in an embodiment" in various places
throughout this specification are not necessarily all referring to
the same embodiment. In particular, an "embodiment" may be a
system, an article of manufacture, a method, or a product of a
process.
[0072] The components of the embodiments, as generally described
and illustrated in the figures herein, could be arranged and
designed in a wide variety of different configurations. Some of the
infrastructure and manufacturing processes that can be used with
embodiments disclosed herein are already available. Accordingly,
well-known structures and manufacturing processes associated with
magnets, connectors, plastics, forms, metals, composites, and the
like, have not been shown or described in detail to avoid
unnecessarily obscuring descriptions of the present exemplary
embodiments. In addition, the steps of the described methods do not
necessarily need to be executed in any specific order, or even
sequentially, nor need the steps be executed only once, unless
otherwise specified.
[0073] The embodiments of the disclosure are best understood by
reference to the drawings, wherein like parts are designated by
like numerals throughout. In the following description, numerous
details are provided to give a thorough understanding of various
embodiments. However, the embodiments disclosed herein can be
practiced without one or more of the specific details, or with
other methods, components, materials, etc. In other instances,
well-known structures, materials, or operations are not shown or
described in detail to avoid obscuring aspects of this
disclosure.
[0074] FIG. 1A illustrates a multi-pole magnetic assembly 100
configured with four magnetic sections 101, 103, 105, and 107 of
alternating polarities. As illustrated, multi-pole magnetic
assembly 100 may include a first half 111 and a second half 112
extending along a longitudinal axis 110. First half 111 may
comprise a first magnetic section 101 having a first magnetic
polarity (north) and a second magnetic section 105 having an
opposite magnetic polarity (south). Second half 112 may include a
corresponding number of magnetic sections 103 and 107 having a
magnetic polarity opposite that of an adjacent magnetic section 101
and 105, respectively, in first half 111.
[0075] FIG. 1B illustrates another embodiment of a multi-pole
magnetic assembly 120 similar to that of FIG. 1A. As illustrated,
multi-pole magnetic assembly 120 may include eight magnetic
sections 121-128, each magnetic section having a magnetic polarity
opposite that of each adjacent magnetic section. Again, multi-pole
magnetic assembly 120 may include a first half and a second half
extending along a longitudinal axis. Each half may include a
corresponding number of magnetic sections. As illustrated, a left
half may include four magnetic sections 121, 123, 125, and 127
having magnetic polarities north, south, north, south,
respectively. A right half may include four corresponding magnetic
sections 122, 124, 126, and 128, each having a magnetic polarity
opposite that of the adjacent magnetic section in the left half.
Accordingly, magnetic sections 122, 124, 126, and 128 may have
magnetic polarities south, north, south, north, respectively.
[0076] FIG. 1C illustrates a multi-pole magnetic assembly 130
configured with any number of magnetic sections 131-N2, with each
magnetic section having a magnetic polarity opposite that of each
adjacent magnetic section. As conveyed by FIG. 1C, a multi-pole
magnetic assembly 130 may include any number of magnetic sections
as desired. According to various embodiments, a magnetic assembly
may include an equal number of magnetic sections with a north
polarization as a south polarization. Additionally, the magnetic
strength of the magnetic sections having a south polarization may
be equal to the magnetic strength of the magnetic sections having a
north polarization. According to some embodiments, the volume
and/or mass of the magnetic sections having a south polarization
may be less than or greater than the volume and/or mass of the
magnetic sections having a north polarization.
[0077] According to some embodiments, the adjacent oppositely
polarized magnetic sections may strengthen or otherwise modify the
magnetic fields of other magnetic sections. In some embodiments,
the assemblies may be configured such that the magnetic field of
one or more outer magnetic sections magnify the magnetic field of
one or more of the center magnetic sections. For example, magnetic
section 134 may have an increased magnetic flux adjacent thereto
due to the interaction of magnetic flux from adjacent magnetic
sections 132 and 136. This may lead to the inner magnetic sections
having greater lifting strength than the outer magnetic
sections.
[0078] FIG. 2 illustrates a multi-pole magnetic assembly 200
configured with six magnetic sections 210-235, each magnetic
section having a magnetic polarity opposite that of each adjacent
magnetic section. As illustrated, magnetic sections 220 and 225 may
be configured with opposite polarities (south and north,
respectively) and may be physically larger magnetic sections than
magnetic sections 210, 215, 230, and 235. According to some
embodiments, magnetic sections 220 and 225 may have a stronger
magnetic strength than magnetic sections 210, 215, 230, and 235.
Alternatively, any magnetic section or pair of magnetic sections
having opposite polarities may have a stronger magnetic strength
than another magnetic section or pair of magnetic sections,
independent of physical shape, volume, weight, or dimensions.
[0079] FIGS. 1A-2 illustrate various embodiments of multi-pole
magnetic assemblies 100, 120, 130, and 200 having cylindrical
configurations. As illustrated in FIGS. 3A and 3B, a multi-pole
magnetic assembly may be any shape or size. FIG. 3A illustrates a
multi-pole magnetic assembly 300 configured with eight magnetic
sections 305-340 each having a magnetic polarity opposite that of
each adjacent magnetic section. As illustrated, multi-pole magnetic
assembly 300 may be in an oblong, or egg-shaped configuration. The
length, width, height, and/or contour of the perimeter of
multi-pole magnetic assembly 300 may be adapted or modified as is
deemed suitable for a particular application.
[0080] Providing another alternative configuration, FIG. 3B
illustrates a multi-pole magnetic assembly 350 configured with six
magnetic sections 360-385, each having a magnetic polarity opposite
that of each adjacent magnetic section. Multi-pole magnetic
assembly 350 is a rectangular prism configuration. According to
various embodiments, the length, width, and height of magnetic
assembly 350 may be adapted for a particular application.
[0081] The various embodiments of multi-pole magnetic assemblies
described in conjunction with FIGS. 1A-3B are merely illustrative
and are not the only contemplated shapes, sizes, or configurations.
Additional shapes and sizes of multi-pole magnetic assemblies are
contemplated having any of a wide variety of shapes and sizes,
including any polygonal regular or irregular prismic, circular
cylindrical, and/or elliptical cylindrical shape. Prismic
multi-pole magnetic assemblies may include bases at right angles,
obtuse angles, and/or acute angles. Moreover, the perimeter may be
irregular and/or include a non-flat base, such as the oblong
multi-pole magnetic assembly illustrated in FIG. 3A.
[0082] A multi-pole magnetic assembly may be formed using any of a
wide variety of magnetizable materials. A multi-pole magnetic
assembly may be a single continuous magnetic material including a
plurality of adjacent magnetic sections each polarized with a
magnetic polarity opposite that of each adjacent magnetic section.
Alternatively, a multi-pole magnetic assembly may be a single
physical material including a plurality of adjacent magnetic
sections each polarized with a magnetic polarity opposite that of
each adjacent magnetic section, where each pair of oppositely
polarized magnetic sections is separated from another pair of
oppositely polarized magnetic sections by a non-magnetically
polarized section of material. According to yet another embodiment,
a multi-pole magnetic assembly may be formed by joining multiple
pairs of oppositely polarized magnetic sections. In such an
embodiment, a multi-pole magnetic assembly may include a plurality
of magnets polarized along their longitudinal axes magnetically
linked end to end, such that each magnetic section is magnetically
polarized opposite that of each adjacent magnetic section.
[0083] FIG. 4 illustrates a cylindrical multi-pole magnetic
assembly 450 encased within a connection member comprising a
cylindrical enclosure 475. As illustrated, multi-pole magnetic
assembly 450 may include six magnetic sections 410-435, each
magnetic section 410-435 having a magnetic polarity opposite that
of each adjacent magnetic section. According to various
embodiments, cylindrical enclosure 475 may be a circular cylinder,
as illustrated, or may be an elliptical cylinder. Multi-pole
magnetic assembly 450 may be free to translate within cylindrical
enclosure 475 along a longitudinal axis, or may be longitudinally
fixed. Additionally, multi-pole magnetic assembly 450 may be free
to rotate about its longitudinal axis within cylindrical enclosure
475, or may be fixedly secured within cylindrical enclosure
475.
[0084] Other embodiments are contemplated in which an enclosure is
not necessary. For example, a rod may be positioned to extend
through a central axis of one or more magnetic assemblies to
facilitate the rotation. Such a rod may be positioned within a
cavity or opening positioned within the magnetic connector
apparatus if desired.
[0085] FIG. 5 illustrates a rectangular prismic multi-pole magnetic
assembly 550 encased within a connection member comprising a
cylindrical enclosure 575. Rectangular prismic multi-pole magnetic
assembly 550 may include six magnetic sections 510-535, each
magnetic section 510-535 having a magnetic polarity opposite that
of each adjacent magnetic section. According to various
embodiments, cylindrical enclosure 575 may be a circular cylinder,
as illustrated, or may be an elliptical cylinder. Multi-pole
magnetic assembly 550 may be free to translate within cylindrical
enclosure 575 along a longitudinal axis, or may be longitudinally
fixed. Multi-pole magnetic assembly 550 may be free to rotate about
its longitudinal axis within cylindrical enclosure 575, or may be
fixedly secured within cylindrical enclosure 575.
[0086] FIG. 6 illustrates a cylindrical multi-pole magnetic
assembly 650 encased within a connection member comprising a
triangular prismic enclosure 675. Multi-pole magnetic assembly 650
may include six magnetic sections 610-635, each magnetic section
610-635 having a magnetic polarity opposite that of each adjacent
magnetic section. According to various embodiments, triangular
prismic enclosure 675 may be modified to be any polygonal prismic
enclosure having any number of sides, dimensions, heights, and/or
base angles. Multi-pole magnetic assembly 650 may be free to
translate within prismic enclosure 675 along a longitudinal axis,
or may be longitudinally fixed. Multi-pole magnetic assembly 650
may be free to rotate about its longitudinal axis within prismic
enclosure 675, or may be fixedly secured within prismic enclosure
675.
[0087] FIG. 7A illustrates a connector apparatus 700 comprising two
cylindrical multi-pole magnetic assemblies 710 and 730 configured
to rotatably align polarities in order to magnetically link two
connection members comprising sections 750 and 760 of a fabric. As
illustrated, each multi-pole magnetic assembly 710 and 730 may be
encased within an enclosure 720 and 740, respectively. As
illustrated, the polarities of the magnetic sections of multi-pole
magnetic assembly 710 are not aligned with the magnetic sections of
multi-pole magnetic assembly 730. Accordingly, in the orientation
illustrated in FIG. 7A, multi-pole magnetic assemblies 710 and 730
would repel one another.
[0088] According to various embodiments, the repulsion of the
magnetic sections of multi-pole magnetic assemblies 710 and 730 may
cause one or both of multi-pole magnetic assemblies 710 and 730 to
rotate about a longitudinal axis in order to align the polarities
of the magnetic sections of each of multi-pole magnetic assemblies
710 and 730. This rotation may comprise a rotation of the magnetic
assemblies within a fixed enclosure or, alternatively, may comprise
a rotation of the enclosures themselves, as described in greater
detail below. The transition from FIG. 7A to FIG. 7B illustrates
multi-pole magnetic assembly 710 rotating about its longitudinal
axis in order to magnetically link with multi-pole magnetic
assembly 730.
[0089] According to some embodiments, multi-pole magnetic assembly
710 may rotate about a longitudinal axis within and with respect to
enclosure 720. In such an embodiment, multi-pole magnetic assembly
and enclosure combinations 710, 720 and 730, 740 may be fixedly
attached to fabric sections 750 and 760. Alternatively, multi-pole
magnetic assembly 710 may be fixed within enclosure 720, and
enclosure 720 may be configured to rotate about its longitudinal
axis in order to align the magnetic sections of each of multi-pole
magnetic assemblies 710 and 730. In such an embodiment, Multi-pole
magnetic assembly and enclosure combinations 710, 720 and 730, 740
may be rotatably secured within a hem or other cavity of fabric
sections 750 and 760.
[0090] FIG. 7B illustrates a connector apparatus 700 comprising the
two cylindrical multi-pole magnetic assembly and enclosure
combinations 710, 720 and 730, 740. As illustrated, with the
magnetic sections of each of multi-pole magnetic assemblies 710 and
730 aligned, multi-pole magnetic assembly and enclosure
combinations 710, 720 and 730, 740 may magnetically link with one
another, and thereby link fabric sections 750 and 760. In addition
to linking fabric, such as fabric sections 750 and 760, one or more
multi-pole magnetic assembly and enclosure combinations, such as
multi-pole magnetic assembly and enclosure combinations 710, 720
and 730, 740, may be used to magnetically link any of a wide
variety of materials, components, or products.
[0091] FIG. 8A illustrates a first multi-pole magnetic assembly 825
and a second multi-pole magnetic assembly 850. In this embodiment,
each of the first and second multi-pole magnetic assemblies 825 and
850 include eight magnetic sections. Each magnetic section may have
a magnetic polarity opposite that of each adjacent magnetic
section. As second multi-pole magnetic assembly 850 approaches
first multi-pole magnetic assembly 825, first multi-pole magnetic
assembly 825 may rotate to align the polarities of the respective
magnetic sections of first and second multi-pole magnetic
assemblies 825 and 850 so that they may magnetically link.
[0092] As illustrated in FIG. 8B, the rotation of first multi-pole
magnetic assembly 825 about its longitudinal axis may align the
polarities of its magnetic sections with those of the second
multi-pole magnetic assembly. Once the polarities are properly
aligned, first and second multi-pole magnetic assemblies 825 and
850 may magnetically link along aligned outside perimeters. In an
alternative embodiment, second multi-pole magnetic assembly 850 may
rotate in addition to, or instead of, first multi-pole magnetic
assembly 825.
[0093] FIGS. 8C-8D illustrate first multi-pole magnetic assembly
825 rotating about its longitudinal axis in order to magnetically
link with second multi-pole magnetic assembly 850 along askew outer
perimeters. As illustrated in FIG. 8C, first multi-pole magnetic
assembly 825 may rotate about its longitudinal axis in order to
properly align the respective magnetic sections of first and second
multi-pole magnetic assemblies 825 and 850.
[0094] One result of using multi-pole magnetic assemblies, as
opposed to bi-pole magnets, is that two or more multi-pole magnetic
assemblies may be magnetically linked along outer perimeters that
are longitudinally askew with respect to one another. As
illustrated in FIG. 8D, first multi-pole magnetic assembly 825 may
be magnetically linked to second multi-pole magnetic assembly 850
longitudinally askew by two magnetic sections. In other
embodiments, first multi-pole magnetic assembly 825 may include any
number of magnetic sections, and second multi-pole magnetic
assembly 850 may be magnetically linked along longitudinally askew
outer perimeters by one or more magnetic sections.
[0095] FIGS. 9A-9G illustrate a first multi-pole magnetic assembly
925 and a second multi-pole magnetic assembly 950 rotatably
interacting and maintaining a magnetic link while second multi-pole
magnetic assembly 950 is translated along a longitudinal axis with
respect to first multi-pole magnetic assembly 925. Beginning with
FIG. 9A, first multi-pole magnetic assembly 925 may be magnetically
linked with second multi-pole magnetic assembly 950 along aligned
outer perimeters. Though illustrated as cylindrical herein, first
and second multi-pole magnetic assemblies 925 and 950 may be
cylindrical, spherical, oblong, rectangular, parallelepiped,
trapezoidal, and/or any other suitable shape. Moreover, first and
second multi-pole magnetic assemblies 925 and 950 may each include
a first half and a second half extending along a longitudinal axis,
each half including any number of magnetic sections having magnetic
polarities opposite that of each adjacent magnetic section. As
illustrated in FIGS. 9A-9G, each multi-pole magnetic assembly 925
and 950 includes eight magnetic sections of alternating
polarities.
[0096] In FIG. 9B, second multi-pole magnetic assembly 950 is
longitudinally translated along an outer perimeter of first
multi-pole magnetic assembly 925. As the polarities of the
respective magnetic sections become misaligned, first multi-pole
magnetic assembly 925 may rotate in order to maintain the proper
polarity alignment. Once first multi-pole magnetic assembly 925 has
rotated, second multi-pole magnetic assembly 950 may be
magnetically linked longitudinally askew by one magnetic section,
as illustrated in FIG. 9C. Alternatively, second multi-pole
magnetic assembly 950 may rotate to maintain the proper polarity
alignment.
[0097] Continuing with FIG. 9D, second multi-pole magnetic assembly
950 may be further longitudinally translated with respect to first
multi-pole magnetic assembly 925. Again, as the polarities of the
respective magnetic sections become misaligned, first multi-pole
magnetic assembly 925 may rotate in order to maintain the proper
polarity alignment for first and second multi-pole magnetic
assemblies 925 and 950 to remain magnetically linked. As
illustrated in FIG. 9E, first and second multi-pole magnetic
assemblies 925 and 950 remain magnetically linked longitudinally
askew by two magnetic sections.
[0098] FIG. 9F illustrates second multi-pole magnetic assembly 950
as it is further translated with respect to first multi-pole
magnetic assembly 925. First multi-pole magnetic assembly 925 may
rotate again in order to maintain an attractive polarity alignment
between the respective magnetic sections of first and second
multi-pole magnetic assemblies 925 and 950. As illustrated in FIG.
9G, first and second multi-pole magnetic assemblies 925 and 950 may
remain magnetically linked along askew outer perimeters, such that
a single magnetic section from each multi-pole magnetic assembly
925 and 950 maintains the magnetic link.
[0099] It should be understood from the discussion accompanying
FIGS. 8A-8D and 9A-9F that various embodiments of the multi-pole
magnetic assemblies disclosed herein may have a plurality of
individual connection points with respect to an adjacent multi-pole
magnetic assembly. Typically, each such assembly will have as many
connection points as there are pairs of magnetic sections.
[0100] FIG. 10A illustrates a connection apparatus comprising a
connection member 1000. Connection member 1000 comprises three
connection edges 1003, 1005, and 1007. Connection edge 1003
comprises an open region comprising a connection rod 1004.
Connection rod 1004 extends through a central axis of multi-pole
magnetic assembly 1017 and allows multi-pole magnetic assembly 1017
to rotate around the connection rod 1004. In some embodiments, rod
1004 may comprise an upper rod section and a lower rod section, and
may be connected to a central axis of multi-pole magnetic assembly
1017, but not extend all of the way therethrough. Additionally,
instead of an open region, connection rod 1004 may be positioned
within a cavity formed within a connection member.
[0101] Connection member 1000 also comprises two other connection
edges 1005 and 1007, each of which encloses a multi-pole magnetic
assembly 1018 and 1019 in an enclosure 1013 and 1015, respectively.
Each of the connection edges together make up a triangular
configuration. As illustrated in FIG. 10A, each multi-pole magnetic
assembly 1017, 1018, and 1019 may be configured to rotate about its
longitudinal axis. Thus, each connection edge 1003, 1005 and 1007
of triangle 1000 may include a multi-pole magnetic assembly 1017,
1018, and 1019 adapted to rotate about its longitudinal axis. The
multi-pole magnetic assembly 1017, 1018, and 1019 may rotate
adjacent the connection edge 1003, 1005 and 1007 of triangle 1000
and align the polarities of each of its magnetic sections with
those of another multi-pole magnetic assembly. Accordingly,
triangle 1000 may be magnetically linked at any angle with another
triangle with a similar configuration as triangle 1000, or another
magnetic connector apparatus of another configuration, along any of
sides 1003, 1005 and 1007.
[0102] FIG. 10B illustrates a connection member 1020 comprising
three connection edges or sides 1023, 1025 and 1027 in a triangular
configuration, including a magnetic assembly and enclosure
combination 1037, 1031 and 1038, 1033 and 1039, 1035 adjacent each
connection edge. According to various embodiments, multi-pole
magnetic assemblies 1037, 1038, and 1039 may be cylindrical,
prismic, and/or another shape. Enclosures 1031, 1033, and 1035 may
be cylindrical, prismic and/or another shape. For example, magnetic
assemblies 1037, 1038, and 1039 may be configured as spherical
magnetic assemblies having two or more magnetic sections. In such
an embodiment, enclosures 1031, 1033, and 1035 may be configured as
corresponding spheres or cylinders adapted to encase the spherical
magnetic assemblies.
[0103] Magnetic assemblies 1037, 1038, and 1039 may be configured
to rotate within and with respect to enclosures 1031, 1033, and
1035. Alternatively, magnetic assemblies 1037, 1038, and 1039 may
be fixed within enclosures 1031, 1033, and 1035. In such an
embodiment, magnetic assemblies 1037, 1038, and 1039 may be
configured to rotate about their longitudinal axes. In either
embodiment, enclosures 1031, 1033, and 1035 may rotate about their
longitudinal axes to align the polarities of each magnetic section
of each magnetic assembly 1037, 1038, and 1039 with another
magnetic assembly in order to magnetically link a side 1023, 1025
and 1027 with another object containing a similar magnetic
assembly, such as another triangle similar to triangular connection
member 1020.
[0104] FIG. 10C illustrates a connection member 1040 comprising
three connection edges in a triangular configuration, including a
magnetic assembly and enclosure combination 1057, 1051 and 1058,
1053 and 1059, 1055 adjacent each connection edge 1043, 1045, and
1047. Similar to previously described embodiments, magnetic
assemblies 1057, 1058, and 1059 may be configured to rotate within
and with respect to enclosures 1051, 1053, and 1055. Alternatively,
magnetic assemblies 1057, 1058, and 1059 may be fixed within
enclosures 1051, 1053, and 1055. In such an embodiment, enclosures
1051, 1053, and 1055 may be configured to rotate about their
longitudinal axes. In still another embodiment, enclosures 1051,
1053, and 1055 may be omitted and magnetic assemblies 1057, 1058,
and 1059 may be configured to rotate about their longitudinal axes
within cavities or hollows adjacent sides 1043, 1045, and 1047 of
triangular connection member 1040.
[0105] FIG. 10D illustrates a connection member 1060 comprising
three connection edges 1063, 1065, and 1067 in a triangular
framework. A magnetic assembly and enclosure combination 1078, 1073
and 1079, 1075 may be fixedly attached to each of connection edges
1065 and 1067. According to the illustrated embodiment, enclosures
1073 and 1075 may be fixedly attached to an inner or outer portion
of each side section 1065 and 1067. Magnetic assemblies 1078 and
1079 may be configured to rotate within and with respect to
enclosures 1073 and 1075, so as to align the polarities of each
magnetic section of each magnetic assembly 1078 and 1079 in order
to magnetically link respective connection edges 1065 and 1067 with
another object containing a similar magnetic assembly, such as
another triangle similar to triangular connection member 1060.
Alternatively, a magnetic connector apparatus of another
configuration, such as one having only a single edge or connection
member, may be connected with the magnetic connector apparatus
configured as triangular framework 1060, or any of the other
magnetic connector apparatus disclosed herein. As shown in the
figure, connection edge 1063 comprises a connection rod 1071 that
is attached to, and substantially parallel to, but offset from,
connection edge 1063. Multi-pole magnetic assembly 1077 may be
configured to rotate about connection rod 1071 in order to
magnetically link connection edge 1063 with a connection edge of
another object.
[0106] FIG. 11 illustrates a connection member 1100 comprising
three connection edges or sides 1103, 1105, and 1107 in a
triangular configuration, each connection edge 1103, 1105, and 1107
including a cylindrical enclosure 1111, 1113, and 1115 encasing a
rectangular prismic multi-pole magnetic assembly 1122, 1124, and
1126. According to various embodiments, rectangular prismic
multi-pole magnetic assemblies 1122, 1124, and 1126 may not easily
rotate within enclosures 1111, 1113, and 1115 or may be fixedly
attached within enclosures 1111, 1113, and 1115. Accordingly,
enclosures 1111, 1113, and 1115 may be configured to rotate within
each side 1103, 1105, and 1107, so as to allow the polarities of
each magnetic section of each multi-pole magnetic assembly 1122,
1124, and 1126 to align with the magnetic sections of other
multi-pole magnetic assemblies.
[0107] FIG. 12 illustrates a connection member comprising six
connection edges 1210-1215 in a hexagonal configuration 1200,
including a magnetic assembly and enclosure combination 1201-1206
adjacent each connection edge 1210-1215. As previously described,
the multi-pole magnetic assembly within each magnetic assembly and
enclosure combination 1201-1206 may be configured to rotate with
or, alternatively, with respect to its corresponding enclosure.
[0108] FIG. 13A illustrates a first connector apparatus 1310
comprising a first connection member having four connection edges
arranged in a rectangular configuration, and a second connector
apparatus 1350 comprising a second connection member having four
connection edges 1321-1324. As illustrated, each of the four
connection edges, or sides, of first connector apparatus 1310 may
encase a magnetic assembly and enclosure combination 1311-1314.
According to various embodiments, the multi-pole magnetic
assemblies encased within each magnetic assembly and enclosure
combination 1311-1314 may be may be cylindrical, prismic, and/or
another suitable shape. Similarly, the enclosures themselves may be
cylindrical, prismic and/or another shape.
[0109] Second connector apparatus 1350 may comprise four enclosures
1321-1324, each encasing a multi-pole magnetic assembly 1331-1334.
Enclosures 1321-1324 may be shaped such that they can be connected
end to end and form any number of polygonal shapes. Each multi-pole
magnetic assembly 1331-1334 may rotate within its respective
enclosure 1321-1324 about a longitudinal axis.
[0110] As illustrated in FIG. 13A, as first and second connector
apparatus 1310 and 1350 approach one another, the multi-pole
magnetic assembly within magnetic assembly and enclosure
combination 1314 may rotate to align the respective magnetic
sections of magnetic assembly and enclosure combination 1314 and
multi-pole magnetic assembly 1331. Once the magnetic sections are
aligned, first and second connector apparatus 1310 and 1350 may be
magnetically linked along longitudinally aligned outer perimeters
1315 and 1325, as illustrated in FIG. 13B. Alternatively, either
the multi-pole magnetic assembly 1331 alone, or the enclosure in
magnetic assembly and enclosure combination 1314, may rotate about
a longitudinal axis in order to align the respective magnetic
sections.
[0111] FIG. 14A illustrates a multi-pole magnetic assembly 1485
rotating within a second connector apparatus 1475 in order to
magnetically link with a first connector apparatus 1450 along
longitudinally askew outer perimeters 1455 and 1480. According to
various embodiments, multi-pole magnetic assembly 1485 may rotate
in order to align the respective magnetic sections of multi-pole
magnetic assembly 1485 and the multi-pole magnetic assembly within
magnetic assembly and enclosure combination 1460. According to
alternative embodiments, either the multi-pole magnetic assembly
within the enclosure of magnetic assembly and enclosure combination
1460 or the enclosure of combination 1460 may rotate along a
longitudinal axis instead of multi-pole magnetic assembly 1485.
[0112] As illustrated in FIG. 14B, since each multi-pole magnetic
assembly within each of first and second connector apparatus 1450
and 1475 includes multiple pairs of magnetic sections (as opposed
to just one pair), first and second connector apparatus 1450 and
1475 may magnetically link along longitudinally askew outer
perimeters 1455 and 1480, which, as discussed above, results in
four separate connection points along each of the sides of the two
connector apparatus.
[0113] FIG. 15A illustrates first and second connector apparatus
1550 and 1575 approaching one another. As illustrated, the magnetic
sections within magnetic assembly and enclosure combination 1560
are not aligned with respect to those of multi-pole magnetic
assembly 1585. Accordingly, if first and second connector apparatus
1550 and 1575 were magnetically linked longitudinally aligned along
outer perimeters 1555 and 1580, one of the multi-pole magnetic
assemblies would need to rotate. However, as illustrated in FIG.
15B, first connector apparatus 1550 may magnetically link with
second connector apparatus 1575 such that their respective outer
perimeters 1555 and 1580 are longitudinally askew by a single
magnetic section without any need for magnetic rotation.
[0114] It should also be understood that embodiments are
contemplated in which only one of the two connector apparatus that
are to be connected together includes a rotatable multi-pole
magnetic assembly. As long as one of the multi-pole magnetic
assemblies can rotate, it can be connected with another apparatus
comprising a multi-pole assembly that is fixed and not
rotatable.
[0115] FIG. 16A illustrates a connector apparatus 1600 comprising a
rectangular connection member 1650 in the process of being
magnetically linked to four triangular connection members
1610-1640. Rectangular connection member 1650 and each of
triangular connection members 1610-1640 may include a magnetic
assembly or magnetic assembly and enclosure combination adjacent
each connection edge of each respective connection member
1610-1650. Each magnetic assembly or magnetic assembly and
enclosure combination may be configured to rotate, so as to allow
the polarities of each magnetic section of each multi-pole magnetic
assembly to align with the magnetic sections of a multi-pole
magnetic assembly in an adjacent connection member 1610-1650.
Accordingly, each connection edge of rectangular connection member
1650 may be magnetically linked to a connection edge of one of the
triangular connection members 1610-1640.
[0116] According to various embodiments, the magnetic assembly
within each magnetic assembly and enclosure combination may be
configured to rotate with or, alternatively, with respect to, its
corresponding enclosure. Accordingly, since the magnetic assemblies
are free to rotate, the connection edges of each of rectangular
connection member 1650 and triangular connection members 1610-1640
may be magnetically linked at any angle, and may be pivoted with
respect to one another once linked.
[0117] As illustrated in the transition from FIG. 16A to FIG. 16B,
multi-pole magnetic assemblies 1633 and 1643 may rotate about their
longitudinal axes in order to align the polarities of their
respective magnetic sections in order to magnetically link with
their respective adjacent multi-pole magnetic assemblies within
rectangular connection member 1650.
[0118] FIG. 16B illustrates a connector apparatus 1600 comprising
rectangular connection member 1650 magnetically linked at each
connection edge to a connection edge of each of triangular
connection members 1610-1640. Multi-pole magnetic assemblies 1633
and 1643 have rotated about their longitudinal axes in order to
align and magnetically link with corresponding multi-pole magnetic
assemblies in rectangular connection member 1650.
[0119] According to various embodiments, each of triangular
connection members 1610-1640 may be pivoted with respect to
rectangular connection member 1650 about their respective
magnetically linked sides. Accordingly, triangular connection
members 1610-1640 may be brought together in order to form a
pyramid having a rectangular base and four triangular faces. In
such embodiments, each remaining unlinked connection member of each
of triangular connection members 1610-1640 may be magnetically
linked to a connection edge of another of triangular connection
members 1610-1640. The multi-pole magnetic assemblies in each
connection edge of each of triangular connection member 1610-1640
may rotate about its longitudinal axis, either with or with respect
to an enclosure, in order to align the polarities of the respective
magnetic sections.
[0120] FIG. 17 illustrates a connector apparatus 1700 comprising
four triangular connection members 1710, 1720, 1730, and 1740. Each
triangular connection members 1710, 1720, 1730, and 1740 may
include one or more multi-pole magnetic assembly and enclosure
combinations. Each multi-pole magnetic assembly and enclosure
combination may rotatably allow each connection edge of each of
triangular connection members 1710, 1720, 1730, and 1740 to
magnetically link with another connection edge of another of
triangular connection members 1710, 1720, 1730, and 1740, so as to
form a tetrahedron. According to various embodiments, each
connection edge of each triangular connection member 1710, 1720,
1730, and 1740 may comprise an enclosure and encase a multi-pole
magnetic assembly configured to rotate about its longitudinal
axis.
[0121] Alternatively, each connection edge of each triangular
connection member 1710, 1720, 1730, and 1740 may secure, either
rotatably or fixedly, an enclosure configured to encase one or more
multi-pole magnetic assemblies. In embodiments in which the
connection member fixedly secures an enclosure, the multi-pole
magnetic assembly may be configured to rotate about its
longitudinal axis within and with respect to the enclosure. In
embodiments in which the connection member rotatably secures an
enclosure, the multi-pole magnetic assembly may be configured to
rotate about its longitudinal axis together with the enclosure as
the enclosure rotates.
[0122] According to various embodiments, any polygonal shape may be
used in place of triangular connection members 1710, 1720, 1730,
and 1740 and magnetically link in order to form a polyhedron having
any number of faces. Similarly, any combination of various
polygonal shapes may be magnetically linked in order to form any
number of shapes and/or compositions of shapes. For example, four
rectangular connection members may be linked together with four
triangular connection members in order to form an obelisk.
Moreover, some embodiments may comprise members extending generally
in only a single dimension, such that polygonal shapes may be made
using several separate magnetic connector apparatus, each making up
one side of the polygon.
[0123] As previously described, a multi-pole magnetic assembly may
be formed using a single continuous magnetic material, or
alternatively, a multi-pole magnetic assembly may be formed by
joining multiple pairs of oppositely polarized magnetic sections
linked end to end, such that each magnetic section is magnetically
polarized opposite that of each adjacent magnetic section.
[0124] FIG. 18A illustrates a magnetizing apparatus 1800 configured
with a bottom plate 1801 and a top plate 1802 configured to create
a multi-pole magnetic assembly. As illustrated, top plate 1802 may
be pivoted about hinge 1812 until top plate 1802 is positioned
directly above bottom plate 1801. In alternative embodiments, top
plate 1802 may not be attached to bottom plate 1801 via hinge 1812
and may instead be pressed directly down against bottom plate 1801.
As illustrated, each of bottom 1801 and top 1802 plates may include
one or more grooves 1850 configured to receive a magnetizable
material. Adjacent each groove are magnetizing plates 1820 and 1830
configured to radiate a magnetizable material placed within groove
1850 with magnetic fields of alternating polarity.
[0125] FIG. 18B illustrates the magnetizing apparatus 1800 with two
magnetizable cylinders 1890 and 1891 in place. Once magnetizable
cylinders 1890 and 1891 are in place, top plate 1802 may be pivoted
about hinge 1812 onto bottom plate 1801. A current may be provided
to cables 1810 and 1812 in order to create positive and negative
magnetic fields along magnetizing plates 1820 and 1830,
respectively. The magnetizing plates 1820 and 1830 having
alternating magnetic polarization may magnetize magnetizable
cylinders 1890 and 1891 so as to create a multi-pole magnetic
assembly including a first half and second half extending along a
longitudinal axis. The first half may include magnetic sections of
alternating polarity and the second half may include a
corresponding number of magnetic sections each having a polarity
opposite that of an adjacent magnetic section in the first
half.
[0126] FIG. 18C illustrates an exemplary embodiment of a multi-pole
magnetic assembly 1890 created using the magnetizing apparatus
described in conjunction with FIGS. 18A and 18B. As illustrated,
multi-pole magnetic assembly 1890 includes a first half and second
half extending along a longitudinal axis. The first half includes
three magnetic sections with alternating polarity and the second
half includes three corresponding magnetic sections each polarized
opposite that of the adjacent magnetic section in the first
half.
[0127] FIG. 19 illustrates an exploded view of an embodiment of a
magnetic connector apparatus 1900. Magnetic connector apparatus
1900 comprises a first outer housing piece 1910, an inner retainer
piece 1920, and a second outer housing piece 1930. Four magnet
housings 1940 are coupled with the inner retainer piece 1920. Each
of the magnet housings 1940 are configured to hold a respective
magnet 1945. Magnets 1945 may be positioned within their respective
magnet housings 1940 such that the magnet 1945 can rotate within
the magnet housing 1940.
[0128] In some embodiments, one or more of the magnet housings 1940
may be configured to prevent or at least inhibit the magnets 1945
contained therein from being removed from the housing for safety
purposes. Various features disclosed herein may facilitate this
purpose. For example, one or more of the magnet housings 1940 may
comprise a material that is of high strength and is difficult to
break and/or deform. Examples of such materials include
high-strength metals and other similar materials, such as a
stainless steel metal, titanium, and/or related alloys, composite
materials, such as carbon fiber, and other similar materials.
[0129] In some embodiments, other features may also, or
alternatively, be provided to serve the purpose of inhibiting
removal of the magnets. For example, as described in greater detail
below, one or more magnet housing engaging members may be provided
in order to at least substantially plug one or more openings in the
magnet housings. Additionally, or alternatively, part of the
magnetic connector apparatus, such as inner retainer piece 1920,
may comprise one or more recessed regions that may be configured to
receive one or more portions of the magnet housing to make it more
difficult to remove the magnet housing from the magnetic connector
apparatus.
[0130] The magnet housing may also include one or more openings for
receiving a fastener for coupling the magnet housing to another
portion of the magnetic connector apparatus, as also described in
greater detail below. The magnet housing may also comprise one or
more reinforced regions wherein the material is thicker at
locations that might otherwise be vulnerable to wear, tampering,
and the like. For example, in embodiments comprising openings that
may be plugged by magnet housing engaging members, regions of the
magnet housing adjacent to such openings may be reinforced,
appropriately bent, shaped, or otherwise configured to further
ensure that the magnet contained therein cannot be removed.
[0131] Similarly, areas of the magnet housing adjacent to any
opening for receiving a fastener may be reinforced, appropriately
bent, shaped, or otherwise configured to further ensure that the
magnet contained therein cannot be removed and/or that the magnet
housing cannot be removed from the magnetic connector apparatus.
For example, in the depicted embodiment, a cylindrical portion of
the magnet housing that houses the magnet may be positioned
relative to another portion of the magnet housing, such as a plate
member, as a substantially perpendicular angle. This configuration
is best seen in FIG. 21. In some preferred embodiments, the
fasteners may comprise rivets or other such fasteners that cannot
easily be removed by a user in order to further enhance the safety
features of the apparatus.
[0132] In some embodiments, magnet 1945 may comprise one or more of
the multi-pole magnetic assemblies discussed above. Such assemblies
may comprise a first half and a second half extending substantially
along a longitudinal axis. The first half may comprise at least two
magnetic sections of alternating polarity and the second half may
comprise a corresponding number of magnetic sections. Each magnetic
section in the second half may have a polarity opposite that of an
adjacent magnetic section in the first half such that the polarity
of the magnet alternates along its length.
[0133] Each of the magnet housings 1940, and therefore each of the
magnets 1940, is positioned along a connection edge of the
apparatus 1900. More particularly, connection edges 1902, 1904,
1906, and 1908 of the square-shaped apparatus 1900 each has an
accompanying magnet/magnet housing such that any of these
connection edges may be used to magnetically couple the apparatus
with another magnetic connector apparatus along one or more of the
connection edges.
[0134] In the depicted embodiment, the first outer housing piece
1910 is positioned on an opposite side of the connector apparatus
1900 from the second outer housing piece 1930 such that the inner
retainer piece 1920 is positioned in between the first outer
housing piece 1910 and the second outer housing piece 1930. In some
preferred implementations of methods for manufacturing magnetic
connector apparatus, inner retainer piece 1920 may be sonically
welded to first outer housing piece 1910 and second outer housing
piece 1930, as described in greater detail below.
[0135] FIG. 20 illustrates a close-up view of a portion of inner
retainer piece 1920 of magnetic connector apparatus 1900. More
particularly, FIG. 20 illustrates a magnet housing receiver 1922
that is configured to engage a magnet housing 1940 (not shown in
FIG. 20) to couple the magnet housing 1940 to the inner retainer
piece 1920. Magnet housing receiver 1922 comprises a first magnet
housing engaging member 1923 and a second magnet housing engaging
member 1924. First magnet housing engaging member 1923 is
configured to engage a first end of a magnet housing 1940 and
second magnet housing engaging member 1924 is configured to engage
a second end of the magnet housing 1940 opposite from the first
end.
[0136] In the depicted embodiment, the first and second magnet
housing engaging members, 1923 and 1924 respectively, each comprise
a magnet housing plug that is configured to at least substantially
seal an opening in a magnet housing 1940. In some embodiments, one
or more of the magnet housing engaging members and/or at least a
portion of one or more of the magnet housings may be made up of a
flexible or resilient material that is configured to facilitate
such a sealing function. For example, such material(s) may comprise
one or more of a plastic, rubber, flexible graphite, elastomer,
foam, cork, etc.
[0137] In the depicted embodiment, the first and second magnet
housing engaging members, 1923 and 1924 respectively, are both
formed with an at least substantially circular radius having a
radius of curvature that matches a radius of curvature of a
corresponding portion of a magnet housing 1940. The corresponding
portion of the magnet housing is best seen in FIG. 21, as described
below.
[0138] FIG. 21 illustrates a close-up view of an embodiment of a
magnet housing 1940 that may be suitable for use in some
embodiments of magnetic connector apparatus disclosed herein. As
shown in this figure, magnet housing 1940 comprises a body member
1947 defining a cylindrical cavity. At opposite ends of the
cylindrical cavity, body member 1947 defines openings 1949. One or
both of openings 1949 may be configured to receive a magnet housing
engaging member, such as magnet housing engaging members 1923 and
1924 illustrated in FIG. 20. The cavity defined by body member 1947
is configured to receive a magnet therein, such as magnet 1945.
[0139] In the depicted embodiment, the ends of magnet housing that
define openings 1949 have a formed radius to add to the structural
strength of the device and further prevent the magnet contained
therein from being removed/accessed. Openings 1949 are at least
substantially circular and are formed with a radius of curvature
that at least substantially matches a radius of curvature of one or
more corresponding magnet housing engaging members (in this
embodiment magnet housing engaging members 1923 and 1924). By
providing matching radii of curvature between these components,
access to the magnet 1945 housed within magnet housing 1940 may be
prevented in order to enhance the safety of the device, as
described elsewhere herein.
[0140] The one or more magnet housing engaging members may be
coupled with another component of the device, such as the inner
retainer piece 1920, in a variety of different ways. For example, a
coupling member 1927 may be provided to couple each of the magnet
housing engaging members 1923 and 1924 to inner retainer piece
1920, as illustrated in FIG. 20. Coupling member(s) 1927 may, in
some embodiments, be an integral part of, and thus comprised of the
same material as, the magnet housing engaging members. In other
embodiments, the one or more coupling members may be made up of a
different material. For example, in some embodiments, the coupling
members may be integral with the inner retainer piece 1920, and
thus may comprise a metal, metal alloy, plastic, or other material
that is used to make up inner retainer piece 1920. In any event, it
is preferable that the link between the retainer piece 1920 (or
another portion of the device) and the magnet housing be strong
enough to withstand any foreseeable tampering such that the
magnet(s) housed within the magnet housing(s) are not capable of
being removed with any foreseeable forces resulting from use of the
device.
[0141] Magnet housing 1940 also comprises a first plate member 1942
extending from body member 1947 and a second plate member 1944
extending from an opposite end of body member 1947. Both first
plate member 1942 and second plate member 1944 comprise fastener
openings 1948. Fastener openings 1948 may be configured to receive
a fastener for coupling the magnet housing 1940 to a retainer
piece, such as inner retainer piece 1920. The retainer piece may
therefore include a similar fastener opening for receiving the
fastener. For example, inner retainer piece 1920 includes a
fastener opening 1926 that is configured to be aligned with
fastener openings 1948 in first plate member 1942 and second plate
member 1944 and receive a fastener 1946 therethrough, as
illustrated in FIGS. 19-21. Various fasteners may be used, such as
rivets, screws, bolts, and pins.
[0142] One or more regions on the magnet housing may also be
reinforced, appropriately bent, shaped, or otherwise configured to
further ensure that the magnet housing and/or the magnet contained
therein cannot be removed. For example, in the magnet housing 1940
depicted in FIG. 21, the opposing ends of body member 1947 that are
configured to receive the magnet housing engaging members have
reinforced metal bent in a circular manner to enhance the strength,
and therefore safety, of the magnet housing 1940. Similarly, magnet
housing 2940 comprises reinforced regions adjacent to fastener
opening 1948 in order to serve similar ends. These reinforced
regions may be configured to fit within a recessed region
surrounding fastener opening 1926 on inner retainer piece 1920.
[0143] The inner retainer piece may further comprise one or more
recessed regions for receiving a plate member of a magnet housing.
For example, inner retainer piece 1920 comprises recessed region
1928 that is configured to receive first plate member 1942. A
similar recessed region may be provided on a surface of inner
retainer piece 1920 that is opposite from the surface shown in FIG.
20 for receiving second plate member 1944.
[0144] Other regions of the device may also include recessed
regions. For example, as shown in FIG. 20, the area surrounding
fastener opening 1926 is stamped or otherwise recessed such that an
appropriate fastener, such as a rivet, may be received therein and
such that, once received in the fastener opening, the fastener is
rendered at least substantially inaccessible to a user of the
apparatus for safety purposes. As discussed above, it may be
preferably in some embodiments, also for safety reasons, to provide
a fastener that is not easily removable, such as a rivet or the
like.
[0145] Although the area of the recessed regions 1928 in the
depicted embodiment is substantially rectangular, it should be
appreciated that other shapes are contemplated as well. However,
preferably the shape of the recessed region at least substantially
matches the shape of the corresponding plate member that is
received therein.
[0146] FIG. 22 illustrates a perspective view of magnetic connector
apparatus 1900. As shown in this figure, magnetic connector
apparatus 1900 includes four connection edges 1902, 1904, 1906, and
1908. Each of these connection edges includes a magnet housing 1940
within which is contained a respective magnet (not visible in FIG.
22). One or more of the connection edges can be coupled with a
connection edge of another connector apparatus, as described above,
in order to build an assembly comprising multiple connector
apparatus.
[0147] FIGS. 23A and 23B illustrate cross-sectional views of the
components used to manufacture another embodiment of a magnetic
connector apparatus. FIG. 23A illustrates these components at a
stage prior to undergoing a welding process in one implementation
of a method for manufacturing a magnetic connector apparatus. FIG.
23B illustrates a cross-sectional view of the components shown in
FIG. 23A after undergoing a welding process, which, in some
implementations, may comprise a sonic welding process.
[0148] The components illustrated in FIGS. 23A and 23B that may be
used to manufacture a magnetic connector apparatus 2300 include a
first outer housing piece 2310, an inner retainer piece 2320, and a
second outer housing piece 2330. One or more magnet housings may
also be coupled with one or more of the first outer housing piece
2310, the inner retainer piece 2320, and the second outer housing
piece 2330, as described above. However, a magnet housing is not
depicted in these figures.
[0149] First outer housing piece 2310 comprises a joint weld
protrusion 2311. As described above, joint weld protrusion 2311
comprises a V-shaped ridge. However, as described elsewhere herein,
other shapes/configurations are also contemplated. Joint weld
protrusion 2311 may extend around the entire perimeter of first
outer housing piece 2310. However, other embodiments are also
contemplated in which one or more joint weld protrusions only
extend partially around such a perimeter.
[0150] A similar joint weld protrusion 2331 may be provided on
second outer housing piece 2330, as shown in the figure. As with
joint weld protrusion 2311, joint weld protrusion 2331 may extend
around the entire perimeter of second outer housing piece 2330 or,
alternatively, joint weld protrusion 2331 may extend partially
around the perimeter. Joint weld protrusion 2331, like joint weld
protrusion 2311, comprises a V-shaped ridge. However, in some
embodiments joint weld protrusion 2331 may comprise a different
shape than joint weld protrusion 2311.
[0151] Both first outer housing piece 2310 and second outer housing
piece 2330 also comprise melt chambers, 2302A and 2302B,
respectively. Both melt chamber 2302A and melt chamber 2302B are
shaped with two sides that form a corner cutout shape. When the
first outer housing piece 2310 is approximated with the second
outer housing piece 2330, as shown in FIG. 23B, a joint melt
chamber 2302 is formed. As illustrated in this figure, half of a
first side of joint melt chamber 2302 is formed with one side of
melt chamber 2302A and the other half of the first side of joint
melt chamber 2302 is formed with one side of melt chamber 2302B. A
second side of joint melt chamber 2302 is formed with a separate
side of joint melt chamber 2302A and a third side of joint melt
chamber 2302 opposite from the second side is formed with another
side of joint melt chamber 2302B. The fourth and final side of
joint melt chamber 2302 is formed from a portion of inner retainer
piece 2320.
[0152] As also shown in FIG. 23B, a welding process may cause
material from the joint weld protrusions and/or other portions of
the components used to manufacture the apparatus to melt into joint
melt chamber 2302. Melted material is shown in FIG. 23B at 10.
Melted material 10 may also surround a portion of inner retainer
piece 2320, as also shown in FIG. 23B.
[0153] FIG. 24A illustrates a cross-sectional view of various
components prior to undergoing a welding process in another
implementation of a method for manufacturing another embodiment of
a magnetic connector apparatus. FIG. 24A illustrates these
components at a stage prior to undergoing a welding process in one
implementation of a method for manufacturing a magnetic connector
apparatus. FIG. 24B illustrates a cross-sectional view of the
components shown in FIG. 24A after undergoing a welding process,
which, in some implementations, may comprise a sonic welding
process.
[0154] The components illustrated in FIGS. 24A and 24B that may be
used to manufacture a magnetic connector apparatus 2400 include,
like magnetic connector apparatus 2300, a first outer housing piece
2410, an inner retainer piece 2420, and a second outer housing
piece 2430. One or more magnet housings (not shown in FIGS. 24A and
24B) may also be coupled with one or more of the first outer
housing piece 2410, the inner retainer piece 2420, and the second
outer housing piece 2430, as described above.
[0155] First outer housing piece 2410 comprises a joint weld
protrusion 2411. However, unlike joint weld protrusion 2311, joint
weld protrusion 2411 comprises a relatively flat top and relatively
parallel sides, rather than the relatively pointed tip and slanted
sides of a V-shaped ridge. Joint weld protrusion 2411 may extend
around the entire perimeter of first outer housing piece 2410.
[0156] A similar joint weld protrusion 2431 may be provided on
second outer housing piece 2430, as shown in the figures. As with
joint weld protrusion 2411, joint weld protrusion 2431 may extend
around the entire perimeter of second outer housing piece 2430 or,
alternatively, joint weld protrusion 2431 may extend partially
around the perimeter. Joint weld protrusion 2431, like joint weld
protrusion 2411, comprises a relatively flat top and parallel
sides. However, in some embodiments joint weld protrusion 2431 may
comprise a different shape than joint weld protrusion 2411. In
other embodiments, a joint weld protrusion may only be provided on
one of first outer housing piece 2410 and second outer housing
piece 2430.
[0157] First outer housing piece 2410 also comprises a melt chamber
2402. Melt chamber 2402, unlike melt chambers 2302A and 2302B,
comprises a rounded cutout or a substantially curvate cutout
region. However, unlike melt chamber 2302, melt chamber 2402 only
formed within first outer housing piece 2410. Second outer housing
piece 2430 may also include a melt chamber, but does not in the
embodiment depicted in FIGS. 24A and 24B.
[0158] Thus, when first outer housing piece 2410 is approximated
with second outer housing piece 2430, as shown in FIG. 24B, a joint
melt chamber is formed that is defined in part by curvate cutout
region 2402 and in part by a portion of inner retainer piece
2420.
[0159] As also shown in FIG. 24B, a welding process may cause
material from the joint weld protrusions and/or other portions of
the components used to manufacture the apparatus to melt into the
melt chamber. Melted material is shown in FIG. 24B at 10. Melted
material 10 may also surround a portion of inner retainer piece
2420, as also shown in FIG. 24B.
[0160] Those having skill in the art will appreciate that many
changes may be made to the details of the above-described
embodiments without departing from the underlying principles of the
invention. While the principles of this disclosure have been shown
in various embodiments, many modifications of structure,
arrangements, proportions, elements, materials, shapes,
thicknesses, widths, heights, and components, may be used without
departing from the principles and scope of this disclosure. These
and other changes or modifications are intended to be included
within the scope of the present disclosure.
* * * * *